Spool gun having unitary shielding gas and weld power connector

ABSTRACT

A spool gun having a quick connector connectable to an electrical power source and a gas source is disclosed. A connection line extends from the spool gun and is attached to a connector. The connector both fluidly connects the spool gun to a shielding gas source and electrically connects the spool gun to a power source constructed to generate a welding-type power. Such a spool gun is quickly and efficiently connectable to the gas and power systems required for performing welding processes.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding-type devices and,more particularly, to a connector for a spool gun to communicate bothelectrical power and shielding gas to the spool gun.

Welding-type systems generally include a power source constructed togenerate a welding-type power. The welding-type power is communicated toa torch or a gun via a weld cable that extends between the torch and thepower source. Some systems contain a consumable weld wire that is fed tothe torch. The consumable weld wire can be pushed or pulled using asingle motor wire feeder, or can be push/pulled by a dual motor wirefeeder from or near the power source to the torch. During the weldingprocess, the consumable weld wire is delivered from the torch to a weldpool.

Some other systems include a spool mounted directly on the weld torch tosupply the consumable weld wire to the weld. Such “spool guns” include asupply of consumable weld wire and a wire feeder assembly supported onthe torch. By positioning the source of consumable weld wire and thewire feed assembly on the torch, allows one power source to be used formultiple applications, allows for easier transport, and reduces the sizeof the overall systems. Additionally, the use of a spool gun alsoenables the use of consumable weld wires that cannot physically supportbeing pushed or pulled from the power source to the torch. That is, someconsumable weld wires cannot support the stresses associated with beingpushed and/or pulled from the power source to the torch. Therefore, aspool mounted gun allows the use of lighter gauge and/or less rigidconsumable weld wires, such as aluminum based wire.

The spool gun torch not only must be electrically connected to a powersource, it also requires a shielding gas connection. The electricalconnection is often made by a stud and fastener connection of a weldcable to an appropriate terminal of a power source. Such connectionsusually require a tool, such as a wrench, to loosen and tighten thefasteners associated with the connection.

In addition to electrically connecting the spool gun to a source ofwelding-type power, the spool gun must also be fluidly connected to asource of shielding gas. The shielding gas connection often requiresanother tool to tighten/loosen associated threaded components. The gasconnection is generally separate and distinct from the electricalconnection of the spool gun with the power source. As such, an operatordesiring to perform a welding process with a spool gun must complete twoseparate connections—the shielding gas system connection and theweld-power electrical connection, each requiring a tool to remove andsecure the connections. Accordingly, the operator must also locate orhave on hand the necessary tools required to complete theconnection/disconnection processes. Accordingly, connecting a spool gunto a weld-type power and a shielding gas source is time consuming anddetrimentally affects process efficiency.

It would therefore be desirable to have an assembly and welding-typesystem capable of quickly and efficiently toollessly connecting a spoolgun to electrical power and shielding gas.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a spool gun assembly and welding-typesystem and that solves the aforementioned problems. The spool gunincludes a connector that connects the spool gun to a shielding gassource and an electrical power source without the use of tools.

Therefore, in accordance with one aspect of the present invention, atorch for welding-type systems is disclosed. The torch includes a spoolgun constructed to receive a spool of consumable wire and is connectedto a gas supply hose and an electrical supply cable. The torch includesa single connector connectable to both a source of gas and a source ofelectrical power and is connected to the gas supply hose and theelectrical supply cable to deliver gas and electrical power to the spoolgun.

According to another aspect of the present invention, a welding systemhaving a power source constructed to generate a power signal suitablefor welding-type operations is disclosed. The welding system includes agas supply constructed to provide a shielding gas to a weld. The systemalso includes a torch having a supply of consumable weld wire supportedthereon and a quick connector. The quick connector is constructed toconnect the torch to both the power source and the gas supply.

According to a further aspect of the present invention, a spool gunassembly is disclosed that includes a spool gun handle having a tip atone end, a gas path therethrough, and a power cable attached to a secondend. The gun includes a drum thereon to hold a spool of wire. A weldwire drive assembly is attached to the spool gun handle and isconstructed to deliver a consumable weld wire from the spool of wire toa tip of the spool gun assembly. The assembly includes a unitary meansfor connecting both the gas path to a gas system and the power cable toa power source to deliver welding-type power and shielding gas to thetip of the spool gun assembly.

Various other features and advantages of the present invention will bemade apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate preferred embodiments presently contemplated forcarrying out the invention.

In the drawings:

FIG. 1 is a perspective view of a spool gun connected to a weldingsystem according to one embodiment of the present invention.

FIG. 2 is an elevational view of the welding system shown in FIG. 1 witha cover removed from the power source of the welding system and anoptional bulk shielding gas source fluidly connected to the powersource.

FIG. 3 is a detailed view of the connection between the spool gun andthe power source taken along line 3-3 of FIG. 2.

FIG. 4 is an alternate embodiment of the spool gun shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a welding-type system 10 having a spool gun 12 connected toa power source 14. Spool gun 12 has a drum 16 with a removable cover 18attached thereto. Drum 16 is constructed to receive and dispense asupply of a consumable weld wire therein. Spool gun 12 includes a wirefeeder drive assembly 20 constructed to feed the consumable weld wirefrom drum 16 to a tip 22 of spool gun 12 upon actuation of a trigger 24of spool gun 12. Depression of trigger 24 initiates movement of a feedroller 26 of drive assembly 20. Feed roller 26 is in contact with theconsumable weld wire such that rotation of feed roller 26 results inconsumable weld wire being delivered to tip 22 of spool gun 12.

A shielding gas is also delivered to tip 22 of spool gun 12 duringactuation of trigger 24. A gas hose 28 extends from a handle portion orbody 30 of spool gun 12 to tip 22. Alternatively, it is understood thatgas hose 28 could be a passage formed internally to body 30 of spool gun12. Gas hose 28 fluidly connects tip 22 of spool gun 12 to a connectionline 32 of spool gun 12. Connection line 32 of spool gun 12 communicatesa shielding gas and welding-type electrical power from power source 14to spool gun 12.

Power source 14 also has a grounding cable 34 extending therefrom. Cable34 has a work clamp 36 attached thereto wherein the work clamp isconstructed to securely engage a workpiece 38. When trigger 24 of spoolgun 12 is depressed, consumable weld wire is delivered from tip 22 ofspool gun 12. With trigger 24 depressed, as tip 22 is moved towardworkpiece 38, an arc is eventually generated between the consumable weldwire and the workpiece and a welding-type process is achieved.

Power source 14 has a housing 40 with a handle 42 positioned about theinternal components of the power source. A control panel 44 allows anoperator to control the power source when a cover 46 of housing 40 islocated in a closed position as shown in FIG. 1. A power cord 48 extendsfrom power source 1 4 and is constructed to engage an outlet 50 suchthat power source 14 is powered by a utility grid or the like.Alternatively, it is understood that power source 14 could be powered bya generator internal or external to housing 40. Understandably, thegenerator could also be powered by an internal combustion engine or thelike thereby providing an untethered power source configured to generatepower signals suitable to welding-type applications.

FIG. 2 shows welding-type system 1 0 with the cover of housing 40removed from power source 14 exposing the internal components 52thereof. As shown, power source 14 is not limited to use with spool gun12. In the particular embodiment shown, power source 14 is constructedto include a consumable weld wire 54 fed via a wire feeder 57. However,since spool gun 12 has its own supply of wire 16, consumable weld wire54 is not delivered to spool gun 12. As such, power source 14 isconstructed to be used with multiple different welding-type guns therebyproviding a highly versatile welding-type power source. Alternatively,spool gun 12 is constructed for use with various power sources, such asthose not containing internal weld wire 54.

Power source 14 has a first gas system 55 which includes a pressurevessel 56 secured in power source 14 by a strap 58. Pressure vessel 56is constructed to supply shielding gas to spool gun 12. A regulator 60is connected to an end 62 of pressure vessel 56 such that when pressurevessel 56 is connected to power source 14, shielding gas is delivered toregulator 60 from pressure vessel 56. A hose 64 extends from regulator60 and passes behind a shroud 66 of power source 14. Hose 64 fluidlyconnects regulator 60 to a valve 68, shown in phantom, connected to aselector switch 69. Valve 68 is also fluidly connected to an optionalsecond gas system 70.

Optional second gas system 70 includes a bulk gas cylinder 72 and a bulkregulator 74 connected thereto. A hose 76 extends between power source14 and bulk regulator 74 and removeably connects second gas system 70 topower source 14 at connection 78. Connection 78 fluidly communicatesshielding gas from second gas system 70 to valve 68 having selectorswitch 69 such that an operator can select between first gas system 55and second gas system 70. Such a construction allows power source 14 tobe provided with shielding gas from a bulk cylinder when less mobilityof the power source is required than when shielding gas is provided frompressure vessel 56. When second gas system 70 is disconnected from powersource 14, first gas system 55 provides a lightweight and highlytransportable source of shielding gas supported by power source 14.Handle 42 provides for single-handed transportation of the gas systemequipped power source 14.

Valve 68 is fluidly connected to a clamp, or weld cable port 80 of powersource 14. Weld cable port 80 includes a receptacle 82 constructed toreceive a connector 84 of spool gun 12. Weld cable port 80 isconstructed to attach connection line 32 of spool gun 12 to both awelding-type electrical power signal and a supply of weld shielding gas.Power source 14 includes a securing screw 85 having a T-handle shape andconstructed to engage connector 84 and secure connection line 32 ofspool gun 12 to weld cable port 82 without the use of tools.Alternatively, it is understood connector 84 of spool gun 12 could beconstructed in a quick connectable manner such that connector 84 couldbe connected and removed from power source 14 through manipulation ofthe connector relative to the associated weld cable port without the useof additional clamping screws or the like. Once securely attached topower source 14, connection line 32 of spool gun 12 communicates weldpower and shielding gas from power source 14 to spool gun 12 throughconnector 84.

Connector 84 of spool gun 12 includes a multi-pin control connector 86connectable to power source 14. Multi-pin connector 86 extends fromconnector 84 via a cable 88 and identifies the type of torch connectedto power source 14 and supplies feedback control signals. Accordingly,when spool gun 12 is connected to power source 14, wire feeder 57 isdisabled from supplying consumable weld wire 54 from power source 14 toa torch.

The engagement between connector 84 and receptacle 82 of weld cable port80 is shown in greater detail in FIG. 3. As shown in FIG. 3, connector84 includes a shank 92 extending therefrom. Shank 92 is constructed of aconductive material and communicates a welding-type power from powersource 14 through connection line 32 to the spool gun. Connector 84 hasa pair of grooves 94 formed therein with an O-ring 96 positioned in eachof the grooves to form a seal therebetween. A plurality of orifices 98,or gas openings, are formed radially through shank 92 and are in fluidcommunication with a gas passage 1 00 formed through connector 84 andconnection line 32 of the spool gun.

Receptacle 82 of weld cable port 80 is constructed to snuggly receiveshank 92 of connector 84 therein. A shielding gas port 1 02 is formed inreceptacle 82 and is fluidly connected to valve 68 shown in FIG. 2. Achannel 1 04 is formed in receptacle 82 generally aligned with shieldinggas port 102. When connector 84 is fully inserted into receptacle 82 ofweld cable port 80, O-rings 96 generally flank channel 104 and sealinglyengage receptacle 82 such that shielding gas introduced into channel 104flows through orifices 98 and into gas passage 100. Accordingly,connector 84 communicates both shielding gas and welding-type power frompower source 14 through connection line 32 to the spool gun.

It is understood and within the scope of the claims that the engagementbetween connector 84 and receptacle 82 could be of many specificconstructions other that recited above. For example, receptacle 82 couldbe constructed to threadingly engage an optional threaded portion 106 ofconnector 84. Threaded portion 106 could be located at an end 107 ofconnector 84 or located remotely therefrom. Because no consumable weldwire or shielding gas is passed through end 107 of the connector, end107 could have a closed construction. Opposite threaded portion 106would be a single O-ring and an orifice could be positionedtherebetween. Positioning the orifice between threaded portion 106 andthe single O-ring forms an alternate connector that is quickly andefficiently connectable to a welding-type power source and constructedto communicate both shielding gas and welding-type power to a torchconnected to the power source.

A spool gun equipped according to the present invention is quickly andconveniently connectable to a source of shielding gas and a source ofwelding-type power through a unitary connector. That is, rather thanmaking a first connection to a source of shielding gas and a secondconnection with a source of electrical power, the spool gun according tothe present invention only requires one connection to form a completelyoperable, shielding gas equipped, spool gun operating welding system.Additionally, a spool gun equipped according to the present inventionimproves operator maneuverability of the spool gun by having both thewelding-type power cable and the shielding gas supply line integratedinto a single connection line such that multiple gas/power lines are notpositioned across a work area. Alternatively, it is understood there maybe instances when it is desirable to have a shielding gas line at leastpartially independent from a welding-type power cable.

FIG. 4 shows an alternate embodiment of the present invention. As shownin FIG. 4, a spool gun 110 includes a spool of consumable weld wire 112and a wire feed assembly 114. Spool gun 110 is substantially similar tospool gun 12 shown in FIG. 1 however, spool gun 110 has a gas line 116and an electrical weld power cable 118 generally separate from eachother. As shown in FIG. 4, gas line 116 extends between a tip 120 ofspool gun 110 and a connector 122. Connector 122 engages weld cable port124 similar to connector 84 of spool gun 12 shown in FIG. 2. A gaspassage 126 passes through connector 122 and fluidly connects a gassupply 128 of weld cable port 124 to a gas port 130 of connector 122.Gas port 130 is external to a housing 132 of a welding-type power source134 such that gas line 116 is removably attachable to connector 122 ofspool gun 110. Accordingly, gas line 116 can be connected to alternategas sources aside from gas supply 128.

Weld power cable 118 electrically connects spool gun 112 to power source134 via connector 122. A shank 136 of connector 122 slidingly engages areceptacle 138 of power source 134 and electrically connects weld powercable 118 to power source 134. A plurality of orifices 140 pass throughshank 136 and fluidly communicate shielding gas from gas supply 128 togas passage 126. A pair of O-rings 142 flank orifices 140 and preventgas from passing beyond receptacle 138 other than through gas passage126. Connector 122 fluidly connects spool gun 110 to a shielding gassource and electrically connects spool gun 110 to a welding-type powersignal.

As one skilled in the art will fully appreciate the heretoforedescription of welding devices and reference to welding power,welding-type power, or welders generally, includes welding, cutting, orheating power. Description of a welding apparatus illustrates just oneembodiment in which the present invention may be implemented.

Therefore, one embodiment of the present invention includes a torch forwelding-type systems including a spool gun. The spool gun is constructedto receive a spool of consumable wire and is connected to a gas supplyhose and an electrical supply cable. The torch includes a singleconnector connectable to both a source of gas and a source of electricalpower and is connected to the gas supply hose and the electrical supplycable to deliver gas and electrical power to the spool gun.

Another embodiment of the present invention includes a welding systemhaving a power source constructed to generate a power signal suitablefor welding-type operations. The welding system includes a gas supplyconstructed to provide a shielding gas to a weld, a torch having asupply of consumable weld wire supported thereon, and a quick connector.The quick connector is constructed to connect the torch to both thepower source and the gas supply.

A further embodiment of the present invention includes a spool gunassembly that includes a spool gun handle having a tip at one end, a gaspath therethrough, and a power cable attached to a second end. The spoolgun includes a drum thereon to hold a spool of wire. A weld wire driveassembly is attached to the spool gun handle and is constructed todeliver a consumable weld wire from the spool of wire to a tip of thespool gun assembly. The assembly includes a unitary means for connectingboth the gas path to a gas system and the power cable to a power sourceto deliver welding-type power and shielding gas to the tip of the spoolgun assembly.

The present invention has been described in terms of the preferredembodiment, and it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. A torch for welding-type systems comprising: a spool gun constructedto receive a spool of consumable wire and connected to a gas supply hoseand an electrical supply cable; and a single connector connectable toboth a source of gas and a source of electrical power, the singleconnector connected to the gas supply hose and the electrical supplycable to deliver gas and electrical power to the spool gun.
 2. The torchof claim 1 wherein the single connector has an outer periphery, an innerpassage, and at least one gas opening formed in the outer periphery andconstructed to allow passage of gas to the inner passage of theconnector.
 3. The torch of claim 2 further comprising a pair of groovesformed in the outer periphery of the single connector, the pair ofgrooves generally flanking the at least one gas opening.
 4. The torch ofclaim 3 further comprising a pair of O-rings, wherein one O-ring ispositioned in each groove of the pair of grooves.
 5. The torch of claim1 further comprising a drive assembly attached to the spool gun andconstructed to deliver a consumable weld wire from the spool ofconsumable weld wire to a weld during a welding operation.
 6. The torchof claim 5 further comprising a trigger attached to the spool gun andoperatively connected to the drive assembly.
 7. The torch of claim 1wherein the single connector is constructed to be connected to a powersource configured to generate a welding-type power without use of tools.8. The torch of claim 1 wherein the single connector has a closed endand an outer periphery, at least one groove formed in the outerperiphery remote from the closed end and constructed to receive anO-ring therein.
 9. The torch of claim 7 wherein the connector isconstructed to engage a clamp of the power source, the clamp having aT-handle actuator directly operable by a user.
 10. A welding systemcomprising: a power source constructed to generate a power signalsuitable for welding-type operations; a gas supply constructed toprovide a shielding gas to a weld; a torch having a supply of consumableweld wire supported thereon; and a quick connector constructed toconnect the torch to both the power source and the gas supply.
 11. Thewelding system of claim 10 wherein the quick connector has a threadingformed thereabout and a seal and a gas passage formed through the quickconnector between the threading and the seal.
 12. The welding system ofclaim 10 wherein the gas supply includes a first gas supply and a secondgas supply wherein the first gas supply and the second gas supply arefluidly connected to a valve, the valve constructed to operativelyconnect the quick connector to only one of the first gas supply and thesecond gas supply.
 13. The welding system of claim 10 wherein the quickconnector further comprises a passage therethrough, the passageconstructed to fluidly connect the torch and the gas supply.
 14. Thewelding system of claim 10 further comprising a drive mechanism attachedto the torch and constructed to delivery the supply of consumable weldwire to a weld.
 15. The welding system of claim 10 wherein the quickconnector is toollessly electrically connectable to the power source andfluidly connectable to the gas supply.
 16. The welding system of claim10 wherein the supply of consumable weld wire is further defined as aspool of consumable weld wire and the spool of consumable weld wire issupported on a hub attached to the torch.
 17. The welding system ofclaim 10 further comprising a seal assembly constructed to fluidly sealan engagement between the quick connector and the gas supply.
 18. Aspool gun assembly comprising: a spool gun handle having a tip at oneend, a gas path therethrough, and a power cable attached to a secondend; a drum on the spool gun to hold a spool of wire; a weld wire driveassembly attached to the spool gun handle and constructed to deliver aconsumable weld wire from the spool of wire to a tip of the spool gunassembly; and unitary means for connecting both the gas path to a gassystem and the power cable to a power source to deliver welding-typepower and shielding gas to the tip of the spool gun assembly.
 19. Thespool gun assembly of claim 18 wherein the unitary connecting meansfurther comprises a passage formed therein, the passage constructed tofluidly connect the gas system and the gas path of the spool gun handle.20. The spool gun assembly of claim 18 further comprising a hub attachedto the spool gun handle, the hub constructed to support a supply ofconsumable weld wire.
 21. The spool gun assembly of claim 18 wherein theunitary connecting means is constructed of a conductive material and hasan insulative cover positioned about a portion thereof.